U.S. patent application number 12/203466 was filed with the patent office on 2009-01-29 for impack resistant composite building panel.
Invention is credited to Jeffrey Allen Chambers, Samuel W. Chastain, Jeffrey Alan Hanks, Sassan Hojabr, Karl-Heinz J. Reilmann, Stephen Robert Tanny.
Application Number | 20090025873 12/203466 |
Document ID | / |
Family ID | 38282812 |
Filed Date | 2009-01-29 |
United States Patent
Application |
20090025873 |
Kind Code |
A1 |
Hanks; Jeffrey Alan ; et
al. |
January 29, 2009 |
Impack Resistant Composite Building Panel
Abstract
A composite building panel that includes a fabric reinforcing
sheet between one of the metal skins and the core of the panel. The
fabric reinforcing sheet, which is preferably made from aramid
fibers improves the impact resistance and penetration resistance of
the building panel without substantially increasing weight and
without adding fuel content to the panel system.
Inventors: |
Hanks; Jeffrey Alan;
(Midlothian, VA) ; Chambers; Jeffrey Allen;
(Hockessin, DE) ; Hojabr; Sassan; (Kingston,
CA) ; Tanny; Stephen Robert; (Newark, DE) ;
Chastain; Samuel W.; (Smyrna, GA) ; Reilmann;
Karl-Heinz J.; (Eastman, GA) |
Correspondence
Address: |
Daniel C. Abeles;Eckert Seamans Cherin & Mellott, LLC
44th Floor, 600 Grant Street
Pittsburgh
PA
15219
US
|
Family ID: |
38282812 |
Appl. No.: |
12/203466 |
Filed: |
September 3, 2008 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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11365122 |
Mar 1, 2006 |
7446064 |
|
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12203466 |
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Current U.S.
Class: |
156/321 |
Current CPC
Class: |
B32B 2307/718 20130101;
B32B 7/12 20130101; B32B 15/14 20130101; B32B 27/12 20130101; Y10T
442/656 20150401; Y10T 428/249924 20150401; B32B 2307/3065
20130101; Y10T 428/24967 20150115; B32B 27/04 20130101; Y10T
428/2495 20150115; B32B 2307/558 20130101; Y10T 428/24942 20150115;
B32B 2262/0269 20130101; Y10T 428/24959 20150115; B32B 27/20
20130101; B32B 2607/00 20130101; B32B 15/08 20130101; Y10T 442/648
20150401; Y10T 442/647 20150401; B32B 27/306 20130101; B32B 15/20
20130101; Y10T 442/678 20150401; B32B 27/32 20130101 |
Class at
Publication: |
156/321 |
International
Class: |
C09J 5/06 20060101
C09J005/06 |
Claims
1-16. (canceled)
17. A method of manufacturing a building panel comprising: an outer
metal skin; an inner metal skin; a polymer core; a fabric
reinforcing sheet disposed between one of the metal skins and the
polymer core; a first adhesive disposed between the fabric
reinforcing sheet and the one of the metal skins, the first
adhesive securing the fabric reinforcing sheet to the one of the
metal skins; a second adhesive disposed between the fabric
reinforcing sheet and the polymer core, the second adhesive
securing the fabric reinforcing sheet to the polymer core; and a
third adhesive disposed between the other of the metal skins and
the polymer core, securing the other of the metal skins to the
polymer core; the method comprising; applying a one side of the
fabric reinforcing sheet, having the first adhesive affixed to the
one side of the fabric reinforcing sheet and the second adhesive
affixed to another side of the fabric reinforcing sheet, to the one
of the metal skins; applying the third adhesive to a one side of
the other of the metal skins; providing the polymer core; and
simultaneously applying the another side of the fabric reinforcing
sheet and the one side of the other of the metal skins to the
polymer core.
18. The method of claim 17 wherein the step of applying the one
side of the fabric reinforcing sheet includes the step of applying
the one side of the fabric reinforcing sheet to the outer metal
skin.
19. The method of claim 17 wherein the step of applying a one side
of the fabric reinforcing sheet to the one of the metal skins
comprises the steps of: providing an extended length of the one of
the metal skins; heating a portion of the extended length of the
one of the metal skins; providing an extended length of the fabric
reinforcing sheet with the first adhesive laminated on the one side
of the fabric reinforcing sheet and the second adhesive laminated
on the another side of the fabric reinforcing sheet; pressing a
portion of the one side of the fabric reinforcing sheet with the
first adhesive laminated on it against a surface of the portion of
the extended length of the one of the metal skins; and heating the
portion of the one of the metal skins with the portion of the
fabric reinforcing sheet with the first adhesive pressed against
it.
20. The method of claim 19 wherein the step of applying the third
adhesive to a one side of the other of the metal skins comprises
the steps of: providing an extended length of the other of the
metal skins; heating a portion of the extended length of the other
of the metal skins; providing an extended length of a laminate of
the third adhesive; pressing a portion of the laminate against a
surface of the portion of the extended length of the other of the
metal skins; and heating the portion of the extended length of the
other of the metal skins with the laminate pressed against it.
21. The method of claim 20 wherein the step of simultaneously
applying the another side of the portion of the fabric reinforcing
sheet with the second adhesive laminated on it and the one side of
the other of the metal skins to the polymer core comprises the step
of simultaneously pressing the heated combination of the one of the
metal skins and the reinforcing fabric sheet with the second
adhesive laminated on the another side of the fabric reinforcing
sheet and the heated portion of the other of the metal skins with
the laminate of the third adhesive pressed against it, respectively
each against an opposing side of the polymer core.
22. The method of claim 21 wherein the step of simultaneously
pressing is achieved by running the heated combination of the
portion of the one of the metal skins and the reinforcing fabric
sheet with the second adhesive laminated on the another side of the
fabric reinforcing sheet, a portion of an extended length of the
polymer core and the heated portion of the other of the metal skins
with the laminate of the third adhesive pressed against it
simultaneously through a pair of rollers.
23. The method of claim 22 wherein a predetermined length of the
pressed together combination of the one of the metal skins, the
fabric reinforcing sheet, the polymer core and the other of the
metal skins is periodically cut after it exits the rollers to
provide a continuous manufacturing process over at least the
shorter of the extended lengths of the reinforcing fabric sheets,
the polymer core, the one of the metal skins and the other of the
metal skins.
24. The method of claim 17 wherein the step of providing the
polymer core comprises: extruding an extended length of polymer
core; cooling the extruded polymer core; and reheating the extruded
polymer core before simultaneously applying the another side of the
fabric reinforcing sheet and the one side of the other of the metal
skins to the polymer core.
25. The method of claim 24 wherein the cooling step comprises air
cooling.
26. The method of claim 17 including the step of making the fabric
reinforcing sheet from aramid fibers.
Description
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to building panels. More
specifically, the invention provides an impact resistant exterior
building panel having a fabric reinforcing layer and a polymer core
between a pair of metal skins.
[0003] 2. Description of the Related Art
[0004] The need for reinforced building panels in regions that are
subject to hurricanes and other storms capable of significantly
damaging buildings is increasingly recognized. In many areas of the
United States, building codes are now requiring commercial and
residential structures to be designed to resist the wind loads and
debris impact loads generated by these severe storms. Current
practice for many of these areas is to sheath the exterior surface
of the structure with minimum 5/8 inch thick plywood, before
application of the final building exterior covering. For example,
wall panels in Florida that use composite building panels having
metal skins and polymer cores are typically installed over 5/8 inch
(1.588 cm) thick 5-ply plywood to meet the debris impact load
requirements specified by the Florida building code. Although the
plywood provides excellent impact resistance, its installation
increases costs and build time for the structure. The wall sections
also are heavy, and the wood adds fuel content to the system,
decreasing the overall fire resistance of the structure. There
exists a need to improve the impact resistance of these metal
composite material building panels, to meet the impact requirements
for severe storm resistance, without the use of the plywood
sheathing.
[0005] Methods to improve the impact resistance for metal composite
panels for uses other than building panels are described in other
patents. For example, U.S. Pat. No. 5,092,952 issued to M. G.
Minnick et al. on Mar. 3, 1992, discloses a composite panel having
an aluminum skin and a glass fiber reinforced polypropylene core.
The skin is laminated to the core using an adhesive having an
ethylene/acrylic acid copolymer combined with a linear low density
polyethylene or a thermoplastic styrene/diene block copolymer.
Similar inventions are described in U.S. Pat. No. 5,246,523, issued
to M. G. Minnick et al. on Sep. 21, 1993, U.S. Pat. No. 5,248,367
issued to M. G. Minnick et al. on Sep. 21, 1993 and U.S. Pat. No.
5,248,369, issued to M. G. Minnick et al. on Sep. 28, 1993.
Reinforcement of these panels is provided by the continuous
dispersion of the reinforcing fibers within the polymer core as it
is being produced. This type of reinforcement would not provide the
same impact resistance as a panel having a reinforcing layer
directly adjacent to the outer skin. Furthermore, production of
these panels is more cumbersome.
[0006] Similar approaches to continuous dispersion of fibers into a
polymer core of a metal composite are described in U.S. Pat. No.
6,586,110, issued to D. F. Obershaw on Jul. 1, 2003. This patent
discloses composite structural members having exterior and interior
skins that may be made from metallic sheet, with a core having a
ribbed structure and a resinous or polymeric filler therein. In
some embodiments, sheet molding compounds are used for the inner or
outer portions, and may be reinforced with KEVLAR.RTM. fibers. The
rib structure within the core precludes the use of manufacturing
procedures that could be used without such a ribbed core.
[0007] Approaches to improving the adhesion of the metal skins to
the polymer cores of metal composite material are described in
other patents. One example is U.S. Pat. No. 6,855,432, issued to S.
Hobajar, et al. on Feb. 15, 2005, disclosing an adhesive
composition that is particularly useful for joining aluminum skins
to polymer cores to form composite panels. No method of reinforcing
a panel is disclosed.
[0008] Approaches to bonding parallel aramid fibers inside aluminum
sheets with various adhesive systems are also described in the art.
These materials were designed to provide high performance aerospace
materials for use in wing skins and other aerodynamic control
surfaces and are detailed in patents such as EP 0056289-B1; U.S.
Pat. No. 4,029,838; U.S. Pat. No. 4,500,589; and U.S. Pat. No.
5,227,216. None of these are directed at providing the impact
improvements needed for typical metal composite building panels to
meet the requirements for use in storm prone areas.
[0009] Accordingly, there is a need for an improved building panel
for use in storm prone regions that offers improved impact
resistance without increasing the weight of the panel or
compromising the fire retardation properties of the wall system.
There is a further need for a building panel having good adhesion
between the outer metal skin and interior core components, and
which is easy and inexpensive to manufacture.
SUMMARY OF THE INVENTION
[0010] The present invention provides a metal composite building
panel having a fabric reinforcing sheet disposed between the outer
metal skin and the polymer core.
[0011] The fabric reinforcing sheet is preferably an aramed fiber
sheet, that preferably has a weight of about 5 oz./yd..sup.2 to
about 20 oz./yd..sup.2. It preferably has a thickness of about 0.01
inch (0.254 mm) to about 0.03 inch (0.762 mm). Other high strength
fibers, having a tenacity greater than 10 grams/denier, may be used
as well, for example, high strength polyethylene, polyester or
nylon fibers, or fiberglass.
[0012] The outer skin of the building panel is preferably a metal
such as aluminum, aluminum alloy, stainless steel, galvanized
steel, zinc, or titanium. 3XXX and 5XXX series aluminum alloys are
particularly preferred. The metal skin preferably has a thickness
of about 0.01 inch (0.254 mm) to about 0.03 inch (0.762 mm).
[0013] The polymer core preferably includes a polymer selected from
the group consisting of polyethylene, polypropylene, or other
polyolefin polymers and copolymers thereof. A preferred polymer
core includes polyethylene, with the possible addition of fillers
such as aluminum trihydrate, calcium carbonate, magnesium
hydroxide, and/or others. The thickness of the polymer core may
vary considerably, depending on the thickness and stiffness desired
for the panel, but will typically be less than one inch (2.54
cm.).
[0014] The metal skins, polymer core, and fabric reinforcing sheet
may be secured together using adhesives or "tie layers" that are
sensitive to heat and/or pressure, such as the class of anhydride
modified polyolefin adhesives sold under the trade names BYNEL.RTM.
or PLEXAR.RTM.. Anhydride modified high density polyethylene
adhesives are preferred, but multi-component polyolefin
compositions such as those described in U.S. Pat. No. 6,855,432,
which is expressly incorporated herein by reference, may be used as
well, with adhesive components selected for their affinity to
different adjacent panel materials. Other thermosetting or
thermoplastic adhesive systems can be used as well, depending on
the materials used for the polymer core and metal skins, for
example, epoxies, polyurethanes, phenol resorcinals, vinyl
acrylates, and other similar adhesives.
[0015] The panel is made by first laminating an adhesive layer to
each side of the fabric reinforcing sheet. The fabric reinforcing
sheet may then be processed as a single layer of fiber-reinforced
adhesive, in the same manner as a simple adhesive layer would be
processed. The combination of the adhesive coated fabric
reinforcing sheet, exterior skin, and polymer core, along with an
additional adhesive between the polymer core and opposing skin, are
then stacked in the appropriate sequence and bonded together using
heat and pressure. The resulting laminated structure may then be
cut into individual panels.
[0016] It is therefore an object of the present invention to
provide a building panel with a fabric reinforcing layer that is
capable of resisting penetration of the panel in standard impact
resistance tests in hurricane prone regions.
[0017] It is another object of the invention to provide a building
panel that is light weight.
[0018] It a further object of the invention to provide a building
panel system that reduces fuel content, and meets approval
standards in regions wherein plywood-reinforced panels are no
longer acceptable.
[0019] It is another object of the present invention to provide a
building panel that may be manufactured with only minimal
modification to the manufacturing equipment lines presently used
for composite building panels.
[0020] These and other objects of the invention will become more
apparent through the following description and drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] FIG. 1 is a cross sectional edge view of one embodiment of a
building panel according to the present invention.
[0022] FIG. 2 is an edge cross sectional view of another embodiment
of a building panel according to the present invention.
[0023] FIG. 3 is a schematic view of a manufacturing process for a
composite panel of the present invention.
[0024] Like reference characters denote like elements throughout
the drawings.
DETAILED DESCRIPTION
[0025] The present invention provides a reinforced building panel
providing improved impact resistance without adding substantial
additional weight or adding fuel content as occurred with prior
composite panels.
[0026] Referring to FIG. 1, one embodiment of a composite panel 10
is illustrated. The panel 10 includes an outer skin 12 and inner
skin 14, with a core 16 disposed therebetween. A fabric
reinforcement sheet 18 is disposed between the core 16 and outer
skin 12. An adhesive layer 20 secures the outer skin 12 to the
fabric reinforcing sheet 18. Likewise, an adhesive 22 secures the
fabric reinforcing sheet 18 and core 16 together. Another adhesive
24 secures the core 16 to the inner skin 14.
[0027] The outer skin 12 and inner skin 14 are preferably made from
a metal such as aluminum, aluminum alloys, stainless steel,
galvanized steel, zinc, or titanium. Preferred metals include 3XXX
and 5XXX series aluminum alloys, with 3105 aluminum alloy being
particularly preferred. The outer skin 12 and inner skin 14
preferably have a thickness of about 0.01 inch (0.254 mm) to about
0.03 inch (0.762 mm), with a thickness of about 0.01 inch (0.254
mm) to about 0.02 inch (0.508 mm) being more preferred.
[0028] The core 16 is preferably made from a polymer having a
density greater than 20 lb./ft..sup.3 (328.382 kg./m..sup.3).
Preferred polymers include polyethylene and other polyolefins, with
the possible addition of fillers such as aluminum tri-hydrate,
calcium carbonate, magnesium hydroxide and/or others known to those
skilled in the art of composite panels. The thickness of the
polymer core may vary considerably, but will typically be less than
about one inch (2.54 cm), and is preferably between about 1.5 mm.
(0.059 inch) and about 5 mm. (0.199 inch).
[0029] The fabric reinforcing sheet 18 is preferably an aramid
fiber sheet having a weight of about 5 oz./yd..sup.2 to about 20
oz./yd.sup.2. A more preferred aramid fiber sheet has a weight of
about 7 oz./yd..sup.2 to about 14 oz./yd.sup.2. An example of a
preferred aramid fiber is marketed under the trademark KEVLAR.
Other high strength fibers, having a tenacity greater than 10
grams/denier, may be used as well, for example, high strength
polyethylene, polyester or nylon fibers, or fiberglass.
[0030] The adhesive layers 20, 22, 24 may be a multi-component
anhydride modified polyolefin adhesive, or anhydride modified high
density polyethylene adhesive. Examples of preferred polyethylene
adhesives are sold under the trademarks PLEXAR.RTM. and BYNEL.RTM..
The adhesive layers 20, 22, 24 preferably have a thickness between
about 0.002 inch (0.051 mm) and 0.006 inch (0.152 mm).
[0031] FIG. 2 illustrates another embodiment of a building panel
26. The panel 26 includes an outer skin 28 and inner skin 30. A
core 32 is disposed between the outer skin 28 and inner skin 30. A
fabric reinforcing sheet 34 is disposed between the core 32 and
outer skin 28. An adhesive layer 36 secures the fabric reinforcing
sheet 34 to a core 32. Likewise, an adhesive layer 38 secures the
core 32 to the inner skin 30. The adhesive layer 40 between the
fabric reinforcing sheet 34 and outer skin 28 includes two
different adhesive layers bound together, with the first adhesive
layer 42 being adjacent to the outer skin 28 and having an affinity
for the outer skin 28, and the second layer 44 being adjacent to
the fabric reinforcing sheet 34, and having an affinity for the
fabric reinforcing sheet 34.
[0032] As before, the outer skin 28 and inner skin 30 are
preferably made from a metal such as aluminum, aluminum alloys,
stainless steel, galvanized steel, zinc, and titanium, with
aluminum alloys being preferred. 3XXX and 5XXX series aluminum
alloys are more preferred with 3105 aluminum alloy being
particularly preferred. The outer skin 28 and inner skin 30
preferably have a thickness between about 0.01 inch (0.254 mm) and
about 0.03 inch (0.762 mm), with a more preferred thickness being
between about 0.01 inch (0.254 mm) to about 0.02 inch (0.051
mm).
[0033] The core 32 is preferably made from a polymer having a
density greater than 20 lb./ft..sup.3 (328.382 kg./m..sup.3).
Preferred polymers include polyethylene and other polyolefins, with
the possible addition of fillers such as aluminum tri-hydrate,
calcium carbonate, magnesium hydroxide and/or others known to those
skilled in the art of composite panels. The thickness of the
polymer core may vary considerably, but will typically be less than
about one inch, and is preferably between about 1.5 mm (0.03 in.).
and about 5 mm (0.059 in.).
[0034] The fabric reinforcing sheet 34 is preferably an aramid
fiber sheet having a weight of about 5 oz./yd..sup.2 to about 20
oz./yd.sup.2. A more preferred aramid fiber sheet has a weight of
about 7 oz./yd..sup.2 to about 14 oz./yd.sup.2. An example of a
preferred aramid fiber is marketed under the trademark KEVLAR.RTM..
Other high strength fibers, having a tenacity greater than 10
grams/denier, may be used as well, for example, high strength
polyethylene, polyester or nylon fibers, or fiberglass.
[0035] The adhesive layers 36, 38 may be either anhydride modified
polyolefin adhesive or anhydride modified high density polyethylene
adhesive. The adhesive layers 36, 38 preferably have a thickness of
about 0.002 inch (0.051 mm.) to about 0.006 inch (0.152 mm.).
[0036] The adhesive layer 40 in this embodiment of the composite
panel 26 includes two layers of adhesive 42, 44. Both layers 42, 44
are preferably anhydride modified polyolefin adhesives composed of
anhydride modified polyethylene or ethylene vinyl acetate. Examples
of preferred adhesives are presently marketed under the trademark
BYNEL.RTM.. Anhydride modified polyethylene is particularly
preferred for layer 42, for binding with the outer skin 28.
Anhydride modified ethylene vinyl acetate is particularly preferred
for the layer 44, for binding with the fabric reinforcing sheet
34.
[0037] The composite panels 10, 26 are made by first laminating the
appropriate adhesive layers 20, 22 or 36, 40 to the fabric
reinforcing sheet 18, 34. The combination of the fabric reinforcing
sheet and adhesive layers is then stacked along with the outer skin
12, 28, inner skin 14, 30, core 16, 32, and adhesive 24, 38. The
various layers of each panel 10, 26 are adhesively bound together
by the application of heat and/or pressure.
[0038] One example of a process by which a panel 10, 26 may be made
is illustrated in FIG. 3. The appropriate polyolefin or polymeric
resin pellets are introduced at 46 into the extruder 48, which
extrudes a core layer 50 of the preselected thickness. After the
core 50 undergoes air cooling at 52, it passes through a reheat
oven 54.
[0039] Aluminum sheet 56 (for the outer skin 12, 28) and 58 (for
the inner skin 14, 30) is supplied from the rolls 60, 62,
respectively. The sheet 56, 58 is first passed through a preheat
oven 64, 66, respectively. The roll 68 supplies a fabric
reinforcing sheet 18, 34 having the adhesive layers 20, 22 or the
adhesive layers 36, 40 already laminated thereto. The rolls 70
supplies an adhesive layer 24, 38. The combination 72 of the sheet
56 and reinforcing layer from the roll 68 pass through the oven 74.
Likewise, the combination 76 of the sheet 58 plus the adhesive
layer from the roll 70 pass through the oven 78. The
metal/reinforcing layer combination 72 and metal/adhesive
combination 76 may then be directed around the rollers 80, 82,
respectively, and are then subsequently directed around the rollers
84, 86, respectively.
[0040] As the core layer 50, metal/reinforcing layer combination
72, and metal/adhesive layer combination 76 pass between the
rollers 84, 86, the layers are pressed together into a single
laminated structure 88 that is secured together by the various
adhesive layers therein, which have been activated by heat and/or
pressure. The laminated structure 88 is then air cooled at 90, and
cut into individual panels 92 by a cutting device 94. The cutting
device 94 may be a saw. The individual panels 92 may then be
stacked and packaged for shipment.
[0041] Those skilled in the art of composite panels will recognize
that the above disclosed procedure employs a similar manufacturing
equipment line to that presently used for manufacturing prior art
metal composite panels. A metal composite panel of the present
invention is particularly advantageous because a laminated
structure consisting of a fabric reinforcing sheet 18, 34, and the
adhesive layers 20, 22, or 36, 40 may be processed exactly as a
single adhesive layer, without any fabric reinforcement, may be
processed. It has been found that a panel 10, 26 of the present
invention will withstand the impact of a 15 lb. (6.803 kg.) 2
in..times.4 in. (5.08 cm..times.10.16 cm.) timber projectile
traveling at 50 ft./sec. (15.24 m./sec.) without being penetrated
by the timber.
[0042] A building panel 10, 26 of the present invention retains
substantially the same fire resistant properties as a prior art
building panel without a fabric reinforcing sheet 18, 34, unlike
presently used plywood reinforced composite panels. The panel 10,
26 also remains relatively lightweight. The composite panels 10, 26
are easy to manufacture, requiring only minor modifications of
presently used manufacturing procedures.
[0043] While a specific embodiment of the invention has been
described in detail, it will be appreciated by those skilled in the
art that various modifications and alternatives to those details
could be developed in light of the overall teachings of the
disclosure. Accordingly, the particular arrangements disclosed are
meant to be illustrative only and not limiting as to the scope of
the invention which is to be given the full breadth of the appended
claims and any and all equivalents thereof.
* * * * *